JP4540106B2 - Manufacturing method of brush holder - Google Patents

Description

  The present invention relates to a method for manufacturing a brush holder provided in a motor.

Conventionally, a DC motor such as a power window device motor is provided with a brush holder for holding a power supply brush. The brush holder includes a holder body for holding the power supply brush inside the motor and a brush holder resin body integrally formed with a connector portion that protrudes outside the motor and can be fitted with an external connector. Some terminals are embedded side by side (see, for example, Patent Document 1).
JP 2003-284292 A

  By the way, in the motor as described above, the circuit component is disposed in a dead space (for example, in a direction orthogonal to a straight line connecting the holder body and the connector portion and opposite to the worm wheel of the speed reduction mechanism). For example, it is conceivable that the terminal is bent at the center to facilitate connection to the circuit component.

  However, if the entire brush holder resin body is molded so that almost the entire terminal including the central portion is embedded, the central portion (bent portion) of the terminal is greatly shaken (twisted) due to pressure during the molding. There is a risk that the central parts of different terminals come into contact with each other. In order to reduce such defects (short-circuits), it may be possible to increase the distance between terminals, but this is difficult due to the limited arrangement space.

  The present invention has been made in order to solve the above-described problems, and an object of the present invention is to provide a brush holder that can reduce contact between a plurality of terminals embedded in a brush holder resin body. It is to provide a manufacturing method.

  The invention according to claim 1 is a method of manufacturing a brush holder in which a plurality of terminals with a bent central portion are arranged side by side and embedded in a brush holder resin body to hold a power supply brush, wherein the central portion Forming a first resin body that is a part of the brush holder resin body so that a part other than the central portion of the plurality of terminals in a substantially linear state is embedded, and the first resin body A first molding step for manufacturing a terminal integrated part holding a plurality of the terminals, a folding step for folding the central portion after the first molding step, and the brush holder resin body after the folding step A second molding step of molding a second resin body that is a part of the brush holder resin body so as to constitute at least a part of the outer shape of the brush holder resin body.

  According to a second aspect of the present invention, in the manufacturing method of the brush holder according to the first aspect, at least two of the plurality of terminals in the first molding step are terminal members connected by a connecting portion, The first forming step includes a cutting step of forming the first resin body so that the connecting portion is exposed, and cutting the connecting portion after the first forming step.

  According to a third aspect of the present invention, in the method for manufacturing a brush holder according to the second aspect, the connecting portion is formed on one end side and the other end side with respect to the central portion of the terminal. And the said cutting process is performed before the said bending process, and each said connection part is cut | disconnected from the same direction.

  According to a fourth aspect of the present invention, in the method for manufacturing the brush holder according to the second or third aspect, in the second molding step, the second resin body is disposed so as to cover a portion where the connecting portion is cut. It integrally molds with respect to the 1st resin body.

  According to a fifth aspect of the present invention, in the brush holder manufacturing method according to any one of the first to fourth aspects, in the first molding step, a part of the outer shape of the brush holder resin body is configured. The first resin body is molded.

  According to a sixth aspect of the present invention, in the method for manufacturing a brush holder according to the fifth aspect, in the first molding step, the first molding step is orthogonal to a facing direction of a pair of molds for performing the second molding step. At least a part of the concave part or the penetrating through-hole or the convex part is formed into a part of the outer shape of the brush holder resin body in the first resin body.

  According to a seventh aspect of the present invention, in the method for manufacturing a brush holder according to the sixth aspect, the opposing direction of a pair of molds for performing the first molding step and a pair of for performing the second molding step. The opposing direction of the mold is a direction in which one end side is sandwiched from the central portion of the terminal, and in the first molding step, the concave portion is formed in the first resin body molded from the central portion of the terminal to the other end side. Or the said through-hole or the said convex part is shape | molded.

  According to an eighth aspect of the present invention, in the method for manufacturing a brush holder according to any one of the first to seventh aspects, the first resin body is at least one of the first molding step and the second molding step. And a connector part in which an external connector can be fitted is formed on at least one of the second resin bodies.

  According to a ninth aspect of the present invention, in the method for manufacturing a brush holder according to any one of the first to eighth aspects, in the second molding step, the second resin body is covered so as to cover a central portion of the terminal. Are integrally molded with the first resin body.

(Function)
According to the first aspect of the present invention, in the first molding step, a portion of the brush holder resin body is embedded so that a portion of the plurality of terminals having a substantially straight central portion excluding the central portion is embedded. A first resin body is molded, and a terminal integrated part in which a plurality of the terminals are held by the first resin body is manufactured. Therefore, the space | interval of several terminals is hold | maintained in the part in which the 1st resin body was shape | molded in terminal integrated components. In the first molding step, since the central portion of the terminal is in a substantially straight state, it is prevented that the central portion is greatly shaken (twisted) during molding of the first resin body, and the center of different terminals is prevented. The parts are prevented from contacting each other.

  And the said center part is bend | folded by a bending process next. Since the space | interval of several terminals is hold | maintained in the part by which the 1st resin body was shape | molded at this time, it is prevented that the center part of a different terminal contacts.

  And the 2nd resin body which is a part of the said resin body is shape | molded by a 2nd shaping | molding process so that at least one part of the external shape of the said brush holder resin body may be comprised. If it does in this way, a brush holder (brush holder resin body) can be manufactured so that the center part of a different terminal may not contact.

  According to the second aspect of the present invention, at least two of the plurality of terminals in the first molding step are terminal members connected by a connecting portion, and the connecting portions are exposed in the first forming step. A first resin body is molded. And since the said connection part is cut | disconnected by a subsequent cutting process, the space | interval of several terminals after the 1st resin body is shape | molded is stably hold | maintained with high precision. Moreover, handling of the terminal until the first molding step is performed becomes easy.

  According to invention of Claim 3, since a connection part is each formed in one end side and the other end side with respect to the center part of the said terminal, one end side with respect to the center part of a terminal, The distance between the terminals on the other end side is stably maintained with high accuracy. And since the connection part formed in the one end side and the other end side with respect to the center part of a terminal is cut | disconnected from the same direction by the cutting process performed before a bending process, a cutting process becomes easy. In other words, if the cutting step is performed after the folding step, it becomes difficult to cut each connecting portion from the same direction, but by performing the cutting step before the bending step, each connecting portion is the same. Can be easily cut from the direction.

  According to invention of Claim 4, a 2nd resin body is integrally molded with respect to a 1st resin body so that the part from which the connection part was cut | disconnected may be covered by a 2nd shaping | molding process. Therefore, for example, it is possible to prevent the brush wear powder or the like from entering the portion where the connecting portion is cut and connect the terminals to each other.

  According to invention of Claim 5, a 1st resin body is shape | molded by a 1st shaping | molding process so that a part of external shape of a brush holder resin body may be comprised. Therefore, for example, the second molding step can be performed while a part of the outer shape of the brush holder resin body is brought into contact with or held by the manufacturing apparatus. As a result, the position of the first resin body with respect to the brush holder resin body (second resin body) can be set with high precision. As a result, the position of the terminal with respect to the brush holder resin body (second resin body) can be set with high precision. Can be set.

  According to the sixth aspect of the present invention, the concave portion or the penetrating through-hole or the convex shape in the direction orthogonal to the opposing direction of the pair of molds for performing the second molding step by the first molding step. At least a part of the convex part is molded into a part that becomes a part of the outer shape of the brush holder resin body in the first resin body. That is, it is difficult to mold the concave concave portion or the through-hole or convex convex portion in the direction orthogonal to the opposing direction of the pair of molds for performing the second molding step in the second molding step. For example, although a slide core is required, a slide core can be made unnecessary by forming at least a part of a concave portion, a through hole, or a convex portion in the first molding step.

  According to the seventh aspect of the present invention, the facing direction of the pair of molds for performing the first molding step and the facing direction of the pair of molds for performing the second molding step are both the center portion of the terminal. This is a direction in which one end side is sandwiched. And a recessed part, a through-hole, or a convex part is shape | molded in the 1st resin body shape | molded by the 1st shaping | molding process to the other end side from the center part of a terminal. That is, the other end side from the center portion of the terminal is a portion that is bent with respect to one end side of the terminal in the bending step after the first forming step, and a recess or the like to be formed with respect to the portion is the first forming step. The concave shape along the opposing direction of a pair of metal mold | die for performing a process may be sufficient. Thereby, a recessed part, a through-hole, or a convex part can be shape | molded easily (without using a slide core).

  According to the invention described in claim 8, a connector portion capable of fitting an external connector to at least one of the first resin body and the second resin body is molded by at least one of the first molding process and the second molding process. The Therefore, a connector part can be formed easily.

  According to invention of Claim 9, a 2nd resin body is integrally molded with respect to a 1st resin body so that the center part of a terminal may be covered by a 2nd shaping | molding process. Therefore, for example, it is possible to prevent the brush wear powder or the like from adhering to the center portion of the terminals and connecting the terminals. Also, the second resin body prevents the bending angle from being bent and the terminal from being displaced due to bending or the like.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the brush holder which can reduce that several terminals embed | buried in a brush holder resin body contact can be provided.

  Hereinafter, an embodiment of the present invention will be described with reference to FIGS. As shown in FIG. 1, a motor 1 for a power window device in a vehicle includes a motor main body 2 and a speed reducing unit 3 for decelerating and outputting the rotation of the motor main body 2.

  As shown in FIGS. 1 and 2, the motor main body 2 includes a yoke housing (hereinafter simply referred to as a yoke) 4 formed in a flat, substantially bottomed cylindrical shape, and a pair of magnets 5 fixed to the inner surface of the yoke 4. (See FIG. 2), an armature (armature) 6 that is rotatably supported in the yoke 4, a brush holder 7, and a pair of power supply brushes 8.

  The brush holder 7 has a brush holder resin body 9 made of a resin material. As shown in FIG. 2, the brush holder resin body 9 includes a holder body 9a, a flange portion 9b, an extension portion 9c, and a connector. The part 9d and the terminal support part 9e are integrally formed. The holder main body 9 a is formed so as to be substantially accommodated in the opening of the yoke 4. A bearing 10 is fixed to the central hole of the holder body 9a, and the tip end side of the rotary shaft 11 of the armature 6 is rotatably supported by the bearing 10. The tip of the rotating shaft 11 protrudes to the outside of the yoke 4, and a sensor magnet 11a is fixed to the protruding portion via a metal plate. A power supply brush 8 is held on the inner side of the yoke 4 in the holder main body 9 a, and the power supply brush 8 is in pressure contact with a commutator 12 fixed to the rotary shaft 11.

  The flange portion 9b is extended to the holder body 9a in a flange shape (outward in the radial direction with the rotation shaft 11 as an axis center). The extension portion 9c is one of the flange portions 9b along the flat surface 4a of the yoke 4 (see FIG. 1, in FIG. 1 and FIG. 2, a plane parallel to the paper surface) (right side in FIG. 1 and FIG. 2). It is formed so as to protrude from the end portion in the external direction (outside in the radial direction), and a connector portion 9d is formed at the tip portion. This connector portion 9d can be fitted with an external connector (not shown) from the direction perpendicular to the flat surface 4a (in FIG. 1 and FIG. 2, the back side of the paper surface in the direction orthogonal to the paper surface and the front side of FIG. 3). Is formed. FIG. 3 is a single product view of the brush holder 7 shown in FIGS. 1 and 2 as viewed from the back side of the drawing. The terminal support portion 9e is formed so as to extend in the axial direction along the rotation shaft 11 from the extension portion 9c. Further, in the terminal support portion 9e of the present embodiment, a concave portion 9f that is concave in the direction perpendicular to the axis (the right direction in FIG. 2) is formed.

  In the brush holder resin body 9, a plurality of terminals T1 to T11 are embedded (insert molding). The terminals T1 to T11 include power supply terminals T1 to T6 and control signal terminals T7 to T11.

  The terminals T1 and T2 are disposed so as to extend in a direction substantially perpendicular to the axis (substantially rightward in FIG. 2) from the inside of the yoke 4 in the holder main body 9a to the extending portion 9c. The power supply brushes 8 are electrically connected to the base ends of the terminals T1 and T2 through pigtails, respectively.

  The terminals T3 to T11 are formed in a shape in which the central portion is bent (at right angles in the present embodiment). Specifically, the terminals T3 and T4 extend in the direction orthogonal to the axis in the extension portion 9c and extend from the connector portion 9d toward the extension portion 9c (leftward in FIG. 2), bend, and further axially ( In FIG. 2, they are arranged so as to extend downward). The terminals T3 and T4 are arranged such that the internal connection terminals T3a and T4a, which are the tip portions, protrude (expose) in the axial direction (downward in FIG. 2) from the tip of the terminal support portion 9e. The distal ends of the terminals T1 and T2 are electrically connected to the base ends of the terminals T3 and T4, respectively.

  Further, the terminals T5 to T11 extend from the connector portion 9d to the extension portion 9c in the direction perpendicular to the axis (left direction in FIG. 2), are bent at the extension portion 9c, and are further extended from the extension portion 9c to the axial direction (FIG. 2). (In the middle, downward direction). The terminals T5 to T11 are arranged such that the internal connection terminals T5a to T11a, which are the tip portions, protrude (expose) in the axial direction (downward in FIG. 2) from the tip of the terminal support portion 9e. The terminals T5 to T11 are arranged so that the external connection terminals T5b to T11b, which are the base ends thereof, are exposed (bent) in the connector portion 9d, and an external connector is fitted to the connector portion 9d. As a result, the terminal is electrically connected to the terminal of the external connector. The terminals T3 to T11 are arranged side by side in the direction perpendicular to the flat surface 4a (the direction perpendicular to the plane of FIG. 2) except for the external connection terminals T5b to T11b (and the vicinity thereof). In FIG. 2, only one internal connection terminal T <b> 3 a to T <b> 11 a is illustrated because it is arranged side by side in the direction perpendicular to the paper surface. Further, the flange portion 9b, the extension portion 9c, and the connector portion 9d in the brush holder resin body 9 are substantially covered with a waterproof member 13 made of an elastomer, except for portions corresponding to the external connection terminals T5b to T11b of the connector portion 9d. Covered.

The speed reduction unit 3 includes a gear housing 21, a worm shaft 22, a worm wheel 23, a clutch 24 (see FIG. 2), a circuit component 25, and a cover 26.
The gear housing 21 is made of a resin material. The gear housing 21 includes a fixed portion 21a, a worm accommodating portion 21b, a wheel accommodating portion 21c, and a circuit accommodating portion 21d.

  The fixing portion 21a is formed in a shape corresponding to the flange portion 4b formed in the opening of the yoke 4, and is fixed to the flange portion 4b and the screw 27, and together with the flange portion 4b, the flange portion 9b in the brush holder 7 is fixed. (Via the waterproof member 13).

  The worm accommodating portion 21b is formed to extend in a cylindrical shape on the extension line of the rotating shaft 11, and supports the worm shaft 22 in a rotatable manner therein. A clutch 24 (see FIG. 2) for drivingly connecting the worm shaft 22 and the rotary shaft 11 is provided on the motor main body 2 side inside the worm housing portion 21b. The clutch 24 operates to lock the rotation of the worm shaft 22 so that the driving force from the rotating shaft 11 is transmitted to the worm shaft 22 and conversely the driving force from the worm shaft 22 is not transmitted to the rotating shaft 11. That is, the clutch 24 is provided to prevent the motor 1 from rotating due to the force applied from the load side.

  The wheel accommodating part 21c is formed in a flat disk shape in a direction orthogonal to the worm accommodating part 21b, and supports the worm wheel 23 rotatably therein. The worm accommodating portion 21b and the wheel accommodating portion 21c are partially communicated with each other, and the worm shaft 22 and the worm wheel 23 are engaged with each other at the communicating portion. The wheel housing portion 21c is formed on the opposite side (left side in FIG. 1) of the connector portion 9d (as the center) with respect to the worm housing portion 21b. Further, the flat surface 21e of the wheel accommodating portion 21c is formed along the flat surface 4a of the yoke 4, and the surface of the gear housing 21 as viewed from the direction orthogonal to the flat surface 21e is called the flat surface of the gear housing 21. It will be.

  The circuit accommodating part 21d is a position corresponding to the internal connection terminals T3a to T11a, and is formed such that the internal connection terminals T3a to T11a are disposed therein. Specifically, the circuit housing portion 21d is on the opposite side of the wheel housing portion 21c (as the center) with respect to the worm housing portion 21b and between the worm housing portion 21b and the connector portion 9d (excluding the circuit component 25). Then, it is formed in the part which becomes the dead space of the motor 1. The circuit housing portion 21d communicates with the motor body 2 side (the portion corresponding to the sensor magnet 11a) inside the worm housing portion 21b. The circuit accommodating portion 21d is formed with an opening 21f that allows the circuit component 25 to be inserted from the direction along the axial direction of the rotary shaft 11 so as to accommodate the circuit component 25. The opening 21f is set such that the opening direction (direction orthogonal to the opening 21f) is inclined with respect to the axial direction of the rotating shaft 11 and the orthogonal direction. The opening 21f of the present embodiment is formed in an inclined straight line connecting the connector portion 9d and the distal end side (opposite side of the motor main body 2) of the worm housing portion 21b when viewed from the direction orthogonal to the flat surface of the gear housing 21. Has been. Each of the internal connection terminals T3a to T11a is disposed at a position where it is exposed (visible) when viewed from the outside in the opening direction of the opening 21f. And the circuit component 25 is substantially accommodated in the circuit accommodating part 21d.

The circuit component 25 includes a holding member 31, a mold IC 32, a heat sink 33, a capacitor 34, a choke coil 35, a Hall IC 36, and the like.
The holding member 31 includes a base member 41 made of a resin material and a plurality of terminals 42 embedded (insert molded) in the base member 41 so that a part thereof is exposed to the outside. The base member 41 of the present embodiment is formed in a substantially plate shape as a whole, and has a convex portion 41 a at a position corresponding to the concave portion 9 f in the brush holder resin body 9.

  A semiconductor element is mounted (embedded) on the mold IC 32. The mold IC 32 is fixed to the holding member 31 so as to be electrically connected to the terminal 42. The motor 1 according to the present embodiment does not include a relay as a drive circuit, and a semiconductor element mounted on the mold IC 32 includes a power MOSFET as a drive circuit. When the mold IC 32 determines that the vehicle window glass has been pinched according to the rotational speed of the sensor magnet 11a (rotary shaft 11) detected by the Hall IC 36, the power supply brush 8 (motor body 2). The anti-pinch control is performed such that a reverse rotation current is supplied to.

The heat sink 33 is made of an aluminum alloy, and is fixed (adhered) to the mold IC 32 in order to dissipate heat generated by the mold IC 32 (semiconductor element).
The capacitor 34 and the choke coil 35 are fixed to the holding member 31 (base member 41) on the opposite side of the mold IC 32, and the terminals thereof are electrically connected to the terminal 42. The Hall IC 36 is fixed at a position corresponding to the sensor magnet 11 a on the holding member 31 (base member 41), and its terminal is electrically connected to the terminal 42.

  The circuit component 25 configured as described above partially protrudes from the opening 21f into the gear housing 21 (circuit accommodating portion 21d) in the state where the motor body 2 and the speed reduction portion 3 are assembled. The armature 6 is assembled in the direction of the rotation axis 10 (along). In the present embodiment, the protrusion 41a of the circuit component 25 is fitted into the recess 9f of the brush holder 7 at this time, so that it is prevented from coming off. And by assembling in this way, a part of several terminal 42 of the circuit component 25 is arrange | positioned so that it can electrically connect with respect to the internal connection terminal T3a-T11a of terminal T3-T11 in the brush holder 7, respectively. . And the some terminal 42 of the circuit component 25 exposed seeing from the opening direction outer side of the opening part 21f is welded and electrically connected to internal connection terminal T3a-T11a, respectively.

  A metal cover 26 is caulked and fixed to the opening 21f of the gear housing 21 so as to close the opening 21f in a state where the circuit component 25 is assembled. The cover 26 radiates heat generated by the mold IC 32 to the outside via the heat sink 33.

  The motor 1 for a power window device configured as described above is disposed in a vehicle door, and an output shaft 23a (see FIG. 1) connected to a worm wheel 23 is connected to a vehicle window glass via a regulator (not shown). Is connected to the drive.

Next, the manufacturing method of the brush holder in the motor 1 comprised as mentioned above is demonstrated.
First, in the “terminal molding step”, a plurality of the terminals T3 to T11 whose central portion is in a straight line state (before being bent) are molded. Specifically, in the present embodiment, as shown in FIGS. 4 (a) and 4 (b), a terminal member TA in which power supply terminals T3 to T6 are connected by connecting portions 51 to 56, and FIG. 5 (a). As shown to (b), the terminal member TB by which the terminals T7-T11 for control signals are connected by the connection parts 61-66 is shape | molded. In addition, the connection parts 51-56 and 61-66 of this Embodiment are one end side and the other end with respect to the center part (Folding curve L shown with a dashed-two dotted line in FIG.4 and FIG.5) of terminal T3-T11. Each side is appropriately formed (in order to maintain a distance between adjacent ones in consideration of rigidity). In the present embodiment, the terminals T3 to T11 (internal connection terminals T3a to T11a and external connection terminals) in a state where the central part is not bent and are connected by the connection parts 51 to 56 and 61 to 66. The symbols (including T5b to T11b) will be described with the same symbols as those in the unconnected state.

  Next, in the “first molding step”, as shown in FIG. 7, the brush holder resin body 9 is embedded so that a part of the terminals T <b> 3 to T <b> 11 (terminal members TA and TB) except for the central portion is embedded. The one end side first resin body 71 and the other end side first resin body 72 as the first resin body that are part of the first resin body are molded. Thereby, the terminal integrated component 73 by which the some terminal T3-T11 was hold | maintained by the one end side 1st resin body 71 and the other end side 1st resin body 72 is manufactured.

  Specifically, in the present embodiment, first, terminal members TA and TB are arranged with terminals T3 to T11 (except for the external connection terminals T5b to T11b and the vicinity thereof) as shown in FIGS. It arrange | positions as follows. Then, one end side is simultaneously formed by a pair of molds (not shown) facing each terminal T3 to T11 (terminal members TA and TB) (vertical direction in FIGS. 6 (a) and 7 (a)). 1 resin body 71 and the other end side 1st resin body 72 are shape | molded, and the terminal integrated component 73 is manufactured. In the present embodiment, one end-side first resin body 71 is molded on one end side with respect to the central portion of terminals T3 to T11 (folded line L indicated by a two-dot chain line in FIGS. 6 and 7), and terminal T3 is formed. The other end side 1st resin body 72 is shape | molded by the other end side with respect to the center part of -T11.

  At this time, the one end side first resin body 71 and the other end side first resin body 72 are exposed so that the connecting portions 51 to 56 and 61 to 66 (see FIGS. 4B and 5B) are exposed. Is molded. In the present embodiment, as shown in FIG. 7 (b), one end-side first resin is formed so that openings 71a to 71c, 72a, and 72b are formed in portions corresponding to the connecting portions 51 to 56 and 61 to 66. The body 71 and the other end side first resin body 72 are molded.

  At this time, the one end-side first resin body 71 and the other end-side first resin body 72 are molded so as to constitute a part of the outer shape (outer surface) of the brush holder resin body 9. In the present embodiment, the one end-side first resin body 71 is formed so that a part of the one end-side first resin body 71 substantially constitutes the connector portion 9 d that is a part of the outer shape of the brush holder resin body 9. In the present embodiment, the other end side first resin body 72 is configured so that a part of the other end side first resin body 72 substantially constitutes the terminal support portion 9e which is a part of the outer shape of the brush holder resin body 9. 72 is formed. At this time, a recess 9 f is formed in a portion of the first resin body 72 on the other end side that is a part of the outer shape of the brush holder resin body 9.

  Next, in the “cutting step”, the connecting portions 51 to 56 and 61 to 66 (see FIG. 4B and FIG. 5B) are cut. Specifically, in the present embodiment, the connecting portions 51 to 56 and 61 to 66 are simultaneously cut from the same direction (the upward direction shown in FIG. 7A and the front side in FIG. 7B). . The cutting at this time is performed by inserting a cutting jig (not shown) into the openings 71a to 71c, 72a, 72b. Thereby, each terminal T3-T11 is made into an independent state, while each space | interval is hold | maintained by the one end side 1st resin body 71 and the other end side 1st resin body 72. FIG.

  Next, in the “bending step”, the central portion of the terminals T3 to T11 (a folding line L indicated by a two-dot chain line in FIG. 7) is bent. In detail, in this Embodiment, as shown in FIG. 8, the center part of terminal T3-T11 is bent at right angle (so that the one end side and other end side with respect to a center part may extend at right angle).

  Next, in the “connection step”, the terminals T1 and T2 (see FIGS. 2 and 8) are connected to one end side of the terminals T3 and T4 (the base end portion and the left end portion in FIG. 7B). Connect and fix the tip of the. At this time, since the other ends of the terminals T3 to T11 are bent with respect to one end side (base end portion), the terminals T1 and T2 are overlapped on one end side (base end portion) of the terminals T3 and T4. Even if welding is simply performed, the other ends of the terminals T3 to T11 do not come into contact with the terminals T1 and T2.

  Next, in the “second molding step”, as shown in FIG. 9, the second resin body that is a part of the brush holder resin body 9 so as to constitute at least a part of the outer shape of the brush holder resin body 9. 81 is formed. In the present embodiment, the second resin body 81 is formed such that the one end side first resin body 71 and the other end side first resin body 72 and the second resin body 81 form the entire brush holder resin body 9. Is molded. That is, in the present embodiment, the holder main body 9a, the flange portion 9b, and the extension are made to the one end side first resin body 71 and the other end side first resin body 72 that substantially constitute the connector portion 9d and the terminal support portion 9e. The second resin body 81 is molded so as to mainly constitute the protruding portion 9c.

  In detail, in this Embodiment, it is the same direction as a pair of metal mold | die not shown in a 1st shaping | molding process, Comprising: It opposes the direction (in FIG. 8, the up-down direction) which sandwiches the one end side of each terminal T3-T11. The second resin body 81 is molded by a pair of molds (not shown). At this time, the concave portion 9f is concave in a direction orthogonal to the opposing direction of a pair of molds (not shown) in the second molding step.

  At this time, the second resin covers the cut portions of the connecting portions 51 to 56 and 61 to 66, that is, fills the openings 71a to 71c, 72a, and 72b (see FIG. 7B). The body 81 is integrally formed with the one end side first resin body 71 and the other end side first resin body 72. At this time, the second resin body 81 is integrally formed with the one end side first resin body 71 and the other end side first resin body 72 so as to cover the central portion of the terminals T3 to T11.

  Next, in the “waterproof member forming step”, as shown in FIG. 3, the waterproof member 13 made of an elastomer is provided so as to substantially cover the flange portion 9b, the extended portion 9c, and the connector portion 9d of the brush holder resin body 9. Mold. Then, the manufacture of the brush holder 7 is completed by electrically connecting the power supply brush 8 (see FIG. 2) to the base ends of the terminals T1 and T2 via the pigtails, respectively.

Next, characteristic effects of the above embodiment will be described below.
(1) The first resin on the one end side so that a part of the plurality of terminals T3 to T11 (terminal members TA, TB) having a substantially straight central portion is buried by the “first molding step” except for the central portion. The body 71 and the first resin body 72 on the other end side are molded, and the terminal integrated part 73 holding the plurality of terminals T3 to T11 is manufactured. Therefore, in the terminal integrated part 73, the space | interval of several terminals T3-T11 is hold | maintained in the part in which the one end side 1st resin body 71 and the other end side 1st resin body 72 were shape | molded. In this “first molding step”, since the central portions of the terminals T3 to T11 are in a substantially straight state, the central portions greatly shake during molding of the first resin body 71 on the one end side and the first resin body 72 on the other end side. (Twisting) is prevented, and the central portions of different terminals are prevented from contacting each other.

  Then, the central portion is bent by the “bending step”. At this time, since the space | interval of several terminals T3-T11 is hold | maintained in the part in which the one end side 1st resin body 71 and the other end side 1st resin body 72 were shape | molded, center part of different terminals T3-T11 Is prevented from touching.

  And the 2nd resin body 81 is shape | molded by the "2nd shaping | molding process" so that the whole brush holder resin body 9 may be formed. If it does in this way, the brush holder 7 (brush holder resin body 9) can be manufactured so that the center part of different terminal T3-T11 may not contact.

  (2) The plurality of terminals T3 to T11 in the “first molding step” are terminal members TA and TB connected by the connecting portions 51 to 56 and 61 to 66, and the connecting portions are connected by the “first molding step”. The one end side first resin body 71 and the other end side first resin body 72 are molded so that 51 to 56 and 61 to 66 are exposed. And since the connection parts 51-56 and 61-66 are cut | disconnected by the subsequent "cutting process", the some terminal after the one end side 1st resin body 71 and the other end side 1st resin body 72 was shape | molded The interval between T3 and T11 is stably maintained with high accuracy. That is, in the “first molding step”, since the central portions of the terminals T3 to T11 are substantially straight, the central portions are greatly shaken (twisted) even when the terminals T3 to T11 are independent of each other. Although it is prevented, since it is connected to the connecting portions 51 to 56 and 61 to 66, the intervals between the plurality of terminals T3 to T11 are stably held with higher accuracy. Further, since the plurality of terminals T3 to T11 in the “first molding step” are the terminal members TA and TB connected by the connecting portions 51 to 56 and 61 to 66, the terminals until the “first molding step” is performed. It becomes easy to handle T3 to T11.

  (3) The plurality of terminals T3 to T11 are two terminal members TA and TB connected by connecting portions 51 to 56 and 61 to 66 for different systems (for power supply and for control signal). That is, as in the present embodiment, it is difficult mechanically (arrangementally) to use a large number of terminals T3 to T11 as one terminal member. It becomes easy to handle the terminals T3 to T11 until the “forming step” is performed.

  (4) Since the connection parts 51-56 and 61-66 are formed in the one end side and the other end side with respect to the center part of terminal T3-T11, respectively, with respect to the center part of terminal T3-T11. Thus, the intervals between the plurality of terminals T3 to T11 are stably held with high accuracy on one end side and the other end side, respectively. In addition, by the “cutting step” performed before the “bending step”, the connecting portions 51 to 56 and 61 to 66 formed on the one end side and the other end side with respect to the central portion of the terminals T3 to T11 are the same. Since it is cut from the direction, the “cutting step” is facilitated. In other words, if the “cutting step” is performed after the “bending step”, it becomes difficult to cut the connecting portions 51 to 56 and 61 to 66 from the same direction. By performing it before the “curving step”, the connecting portions 51 to 56 and 61 to 66 can be easily cut from the same direction.

  (5) The second resin body 81 is connected to the one end side so that the portions (openings 71a to 71c, 72a and 72b) where the connecting portions 51 to 56 and 61 to 66 are cut are covered by the “second molding step”. The resin body 71 and the first resin body 72 on the other end side are integrally molded. Therefore, for example, it is possible to prevent the brush wear powder and the like from entering the portions where the connecting portions 51 to 56 and 61 to 66 are cut to connect the terminals T3 to T11.

  (6) By the “first molding step”, the one end-side first resin body 71 and the other end-side first resin body 72 are molded so as to constitute a part of the outer shape (outer surface) of the brush holder resin body 9. . Therefore, for example, the “second molding step” can be performed while a part of the outer shape of the brush holder resin body 9 is brought into contact with or held by the manufacturing apparatus. Thereby, the position of the one end side 1st resin body 71 and the other end side 1st resin body 72 with respect to the brush holder resin body 9 (2nd resin body 81) can be set with high precision, and, by extension, the brush holder resin body. 9 (second resin body 81), the positions of the terminals T3 to T11 can be set with high accuracy.

  (7) By the “first molding step”, the concave portion 9f that is concave in the direction orthogonal to the opposing direction of the pair of molds for performing the “second molding step” is formed in the first resin body 72 on the other end side. The brush holder resin body 9 is molded into a part that is a part of the outer shape. That is, the concave portion 9f that is concave in the direction orthogonal to the opposing direction of the pair of molds for performing the “second molding step” is difficult to mold in the “second molding step” and requires a slide core. However, by forming the recess 9f in the “first molding step”, the slide core can be made unnecessary. Specifically, the facing direction of the pair of molds for performing the “first molding step” and the facing direction of the pair of molds for performing the “second molding step” of the present embodiment are both terminals T3-3. This is a direction in which one end side is sandwiched from the central portion of T11. And the recessed part 9f is shape | molded in the other end side 1st resin body 72 shape | molded to the other end side from the center part of terminal T3-T11 by a "1st shaping | molding process." That is, the other end side from the central part of the terminals T3 to T11 is a part that is bent with respect to one end side of the terminals T3 to T11 in the bending process after the “first molding process”, The concave portion 9f to be molded may have a concave shape along the opposing direction of the pair of molds for performing the “first molding step”. Thereby, the recessed part 9f can be shape | molded easily (without using a slide core).

  (8) The connector portion 9d into which the external connector can be fitted is formed by the “first forming step” and the “second forming step” (mainly the first forming step). Therefore, the connector part 9d can be formed easily.

  (9) The second resin body 81 is integrally molded with the first resin body 71 on the one end side and the first resin body 72 on the other end side so as to cover the central portion of the terminals T3 to T11 by the “second molding step”. Is done. Therefore, for example, it is prevented that brush wear powder etc. adhere to the center part of terminal T3-T11 and terminal T3-T11 will be connected. Further, the second resin body 81 prevents the bending angle from being bent at the center and the terminals T3 to T11 from being displaced due to bending or the like.

The above embodiment may be modified as follows.
In the above embodiment, the plurality of terminals T <b> 3 to T <b> 11 in the “first molding step” are connected by the connecting portions 51 to 56 and 61 to 66 for different systems (for power supply and for control signal). Although the terminal members TA and TB are used, at least two of the terminals may be modified to include at least one other terminal member connected by a connecting portion. The plurality of terminals T3 to T11 may be independent from the “first molding process” (“terminal molding process”). In this case, of course, the openings 71a to 71c, 72a, 72b, the “cutting step” and the like are not necessary. Moreover, although the connection parts 51-56 and 61-66 were each formed in the one end side and the other end side with respect to the center part of terminal T3-T11, respectively, it is one end with respect to the center part of terminal T3-T11. You may form only in either one of the side and the other end side.

  In the above embodiment, the first resin body at the one end side so that the openings 71a to 71c, 72a and 72b are formed in the portions corresponding to the connecting portions 51 to 56 and 61 to 66 by the “first molding step”. 71 and the other end side first resin body 72 are formed, but if the connecting portions 51 to 56 and 61 to 66 (see FIG. 4B and FIG. 5B) are exposed, the structure is changed to another configuration. May be. For example, the one end side first resin body 71 and the other end side first resin body 72 are pluralized so that the connecting portions 51 to 56 and 61 to 66 (see FIGS. 4B and 5B) are exposed. You may divide and shape.

  In the above embodiment, the first-end-side first resin body 71 and the other-end-side first resin body 72 so as to constitute a part (outer surface) of the outer shape of the brush holder resin body 9 by the “first molding step”. However, the present invention is not limited to this, and the first resin body (the first resin body 71 on one end side and the first resin body 72 on the other end side is molded so that everything is covered later in the “second molding step”. ) May be molded.

  In the above embodiment, the concave portion 9f is formed in the first resin body 72 on the other end side by the “first molding step”, but may be embodied in a manner in which the concave portion 9f is not formed in the brush holder resin body 9. Then, the concave portion 9f may be formed using a slide core when performing the “second forming step”. Also, through holes (at least at least through the first resin body 72 on the other end side in the “first molding step”) that penetrate in the direction perpendicular to the opposing direction of the pair of molds for performing the “second molding step”. A part) may be formed, or a convex part (at least a part thereof) convex in the same direction may be formed. Even in these cases, the through hole and the convex portion can be easily formed (for example, without using a slide core).

  In the above embodiment, the facing direction of the pair of molds for performing the “first molding step” and the facing direction of the pair of molds for performing the “second molding step” are both terminals T3 to T11. It is said that it is the direction (in FIG. 7 (a) and FIG. 8, the up-down direction) which pinches one end side from the center part of this, It is not limited to this, Also good.

  In the above embodiment, the second resin body 81 is covered by the “second molding step” so that the portions (openings 71a to 71c, 72a, 72b) where the connecting portions 51 to 56, 61 to 66 are cut are covered. However, it is not necessary to cover the portion where the connecting portions 51 to 56 and 61 to 66 are cut.

  In the above embodiment, the second resin body 81 is molded so that the central portion of the terminals T3 to T11 is covered by the “second molding step”, but the central portion of the terminals T3 to T11 may not be covered. Good.

  In the above embodiment, the central portion of the terminals T3 to T11 is bent at a right angle by the “bending step”, but the present invention is not limited to this and may be bent at a different angle.

  In the above embodiment, the “connection process” is performed after the “bending process” and before the “second molding process”. However, the “connection process” is based on the configuration of the terminals T1 and T2. It is to be performed, and may be changed as appropriate (the order of execution, etc.) based on the configuration of the terminals T1 and T2.

  In the above embodiment, the entire brush holder resin body 9 is formed by the first resin body 71 at the one end side, the first resin body 72 at the other end side, and the second resin body 81 by the “second molding step”. As described above, the second resin body 81 is molded. However, the present invention is not limited to this, and the second resin body 81 may be changed if the second resin body is molded so as to constitute at least a part of the outer shape of the brush holder resin body 9. For example, after forming the second resin body so as to constitute a part of the outer shape of the brush holder resin body 9 by the “second molding process”, the entire brush holder resin body 9 is further processed by the “third molding process”. May be formed.

  In the embodiment described above, the method for manufacturing the motor 1 used in the power window device is embodied. However, for example, the method may be embodied in a method for manufacturing a motor for another device such as a sunroof motor or a door closer motor.

The technical idea that can be grasped from the above embodiments will be described below together with the effects thereof.
(B) The method for manufacturing a brush holder according to claim 2, wherein the plurality of terminals in the first forming step include a plurality of the terminal members. If it does in this way, the terminal of a different system | strain can be put together (it is set as a terminal member). Therefore, handling of the terminal until the first molding step is performed becomes easy.

The top view of the motor in this Embodiment. FIG. 2 is a partial cross-sectional view of a motor in the present embodiment. The single-piece figure of the brush holder in this Embodiment. (A) (b) Explanatory drawing for demonstrating the manufacturing method of a brush holder. (A) (b) Explanatory drawing for demonstrating the manufacturing method of a brush holder. (A) (b) Explanatory drawing for demonstrating the manufacturing method of a brush holder. (A) (b) Explanatory drawing for demonstrating the manufacturing method of a brush holder. Explanatory drawing for demonstrating the manufacturing method of a brush holder. Explanatory drawing for demonstrating the manufacturing method of a brush holder.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 7 ... Brush holder, 8 ... Brush for electric power feeding, 9 ... Brush holder resin body, 9d ... Connector part, 9f ... Recessed part 51-56, 61-66 ... Connection part, 71 ... One end side 1st as 1st resin body Resin body, 72: first resin body on the other end side as the first resin body, 73: terminal integrated part, 81: second resin body, T3 to T11: terminal.

Claims (9)

A method of manufacturing a brush holder for holding a power supply brush, in which a plurality of terminals with a bent central portion are arranged side by side and embedded in a brush holder resin body,
A first resin body that is a part of the brush holder resin body is molded so that a part of the plurality of terminals in which the central part is in a substantially straight state excluding the central part is embedded, and the first resin body is molded. A first molding step for producing a terminal integrated part in which a plurality of terminals are held by a resin body;
After the first forming step, a bending step of bending the central portion;
A second molding step of molding a second resin body that is a part of the brush holder resin body so as to constitute at least a part of the outer shape of the brush holder resin body after the bending step; A method of manufacturing a brush holder characterized by the above. In the manufacturing method of the brush holder of Claim 1,
At least two of the plurality of terminals in the first molding step are terminal members connected by a connecting portion,
In the first molding step, the first resin body is molded so that the connecting portion is exposed,
A method for manufacturing a brush holder, comprising a cutting step of cutting the connecting portion after the first forming step. In the manufacturing method of the brush holder of Claim 2,
The connecting portions are respectively formed on one end side and the other end side with respect to the central portion of the terminal,
The said cutting process is performed before the said bending process, Each said connection part is cut | disconnected from the same direction, The manufacturing method of the brush holder characterized by the above-mentioned. In the manufacturing method of the brush holder of Claim 2 or 3,
In the second molding step, the second resin body is integrally molded with the first resin body so as to cover a portion where the connecting portion is cut. In the manufacturing method of the brush holder of any one of Claims 1 thru | or 4,
In the first molding step, the first resin body is molded so as to constitute a part of the outer shape of the brush holder resin body. In the manufacturing method of the brush holder according to claim 5,
In the first molding step, at least a part of a concave concave portion or a penetrating through hole or convex convex portion in a direction orthogonal to the opposing direction of the pair of molds for performing the second molding step, A method for manufacturing a brush holder, comprising molding the first resin body into a part of the outer shape of the brush holder resin body. In the manufacturing method of the brush holder of Claim 6,
The facing direction of the pair of molds for performing the first molding step and the facing direction of the pair of molds for performing the second molding step are both directions in which one end side is sandwiched from the central portion of the terminal. And
In the first molding step, the concave portion, the through hole, or the convex portion is molded in a first resin body that is molded on the other end side from the central portion of the terminal. In the manufacturing method of the brush holder of any one of Claims 1 thru | or 7,
At least one of the first molding step and the second molding step is characterized in that a connector portion on which an external connector can be fitted is molded on at least one of the first resin body and the second resin body. Manufacturing method. In the manufacturing method of the brush holder of any one of Claims 1 thru | or 8,
In the second molding step, the second resin body is integrally molded with the first resin body so as to cover the central portion of the terminal.

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